Basichydraulicbysanjayhumania 160618115212

Basic hydraulics
Training program
2
Sanjay Humania 20-01-2016
Objective
The object of this subject is to teach more about
hydraulics and its areas of application.
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Introduction
The controlled movement of parts or a
controlled application of force is a common
requirement in the industries.
These operations are performed mainly by using
electrical machines or diesel, petrol and steam
engines as a prime mover.
Power Energy Control Prime

Load
source medium system mover
4
What is Fluid Power?

Fluid power is the engineering science and
technology that deal with the generation,
control, and transmission of energy through the
use of pressurized fluids.
Or
Fluid power technology is to convert, transmit,
control & apply fluid energy to perform useful
work. Fluid can be either a liquid or gas.
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Hydraulics
The study of hydraulics deals with system
operated with hydraulic oil media to impart
power or to control power.
Hydraulic power is the power that is transmitted
by pressurized oil.
It may be used to power machines or to control
or to regulate machines.
Power
Oil tank / Pressurized Control
source Actuator
reservoir oil valve
(Pump)
Basic principles
7
Historical review
Actual advancement of Oil Hydraulics started
from the end of 17th Century. In 1648, a French
Physicist, Pascal, discovered a fundamental law
underlying the whole science of Hydraulics.
Its a two-part statement as given here:
Pressure at any point in a static fluid is the same
in every direction,
Pressure exerted on a confined fluid is
transmitted equally in all directions, acting with
equal force on equal areas.
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formula:
FORCE FORCE = PRESSURE X
AREA
AREA
PRESSURE PRESSURE = FORCE AREA

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Pressure
Pressure is defined as the force per unit area.
P=F/A
The SI unit for pressure is Pascal (Pa),
1Pa =1N /m^2
The unit for pressure is also Bar (bar), kg / cm2,
1 bar=1.019368kg/cm2
1kg/cm2=0.9810bar
1bar = 105 Pa
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Pressure
Pressure occurs in fluid when it is subjected to
force.
A force F is applied to an enclosed fluid via a
piston area A
This result in a pressure P in the fluid.
Increasing the force increase the pressure P in
direct proportion.
Decreasing the area also increase pressure P
Pressure in the fluid can therefore be define as the
force acting per unit are, or:
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Pascal's law & its applications

Basic law can be applied
to an enclosed hydraulic
system having a cylinder
p1 with a piston area of
10cm2 & another
cylinder p2 with 100cm2.
Both are connected &
filled with water.
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Pascal's law & its applications

Now assume a force of 50N is applied downward on p1,
The Pressure created by P1=Force/Area
=50N/10cm2 = 5N/cm2
A/c to Pascal's law, pressure acts equally in all direction.
So, the pressure acting on p2 is also 5N/cm2 . As the p2
has the area of 100cm2 .
So, Force available on p2 =Pressure X Area
= 5N/cm2 X 100cm2 =500N
The force applied to piston 1 is multiplied 10 times, this
advantage is utilised in fluid power system !!!
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Principle of hydraulic system

The force given by fluid is
given by the multiplication of
pressure and area of cross
section.
As the pressure is same in all
the direction, the smaller
piston feels a smaller force and
a large piston feels a large
force.
Therefore, a large force can be
generated with smaller force
input by using hydraulic
systems.
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Hydraulic systems.
The hydraulic systems consists a number of parts for its
proper functioning.
These include storage tank, filter, hydraulic pump, pressure
regulator, control valve, hydraulic cylinder, piston and leak
proof fluid flow pipelines.
It consists of:
cylinder
storage tank
Filter
electric pump
pressure regulator
control valve
leak proof closed loop piping.
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Schematic of hydraulic system

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Hydraulic systems components

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Hydraulic systems...
The storage/fluid tank is a reservoir for the liquid used
as a transmission media.
The liquid used is generally high density incompressible
oil. It is filtered to remove dust or any other unwanted
particles and then pumped by the hydraulic pump.
The capacity of pump depends on the hydraulic system
design. These pumps generally deliver constant volume
in each revolution of the pump shaft. Therefore, the fluid
pressure can increase indefinitely at the dead end of the
piston until the system fails.
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Hydraulic systems....
The pressure regulator is used to avoid such
circumstances which redirect the excess fluid back to
the storage tank.
The movement of piston is controlled by changing
liquid flow from port A and port B.
The cylinder movement is controlled by using control
valve which directs the fluid flow.
The leak proof piping is also important due to safety,
environmental hazards and economical aspects.
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Types of Hydraulics
The place held by hydraulics in (modern)
automation technology illustrates the wide range
of applications for which it can be used.
A basic distinction is made between:
Stationary hydraulics
Mobile hydraulics
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Stationary hydraulics
Stationary hydraulics is fixed at one station where all the
activities are carried out at the same station. Stationary
hydraulics is used in machine tool applications.
The following application areas are important for
stationary hydraulics:
Production and assembly machines of all types
Transfer lines
Lifting and conveying devices
Presses
Injection moulding machines
Rolling lines
Lifts
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Mobile hydraulic
Mobile hydraulic systems move on wheels or tracks,
for example, unlike stationary hydraulic systems
which remain firmly fixed in one position.
A characteristic feature of mobile hydraulics is that
the valves are frequently manually operated.
Typical application fields for mobile hydraulics
include:
Construction machinery
Excavators, elevating platforms
Lifting and conveying devices
Agricultural machinery
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Applications of hydraulic systems

The hydraulic systems are mainly used for
precise control of larger forces.
The main applications of hydraulic system can
be further classified in five categories:
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Industrial hydraulics
Industrial: Plastic
processing machineries,
steel making and primary
metal extraction
applications, automated
production lines,
machine tool industries,
paper industries, loaders,
crushes, textile
machineries, R & D In modern CNC controlled machine tools, tools and
equipment and robotic work pieces are clamped by means of hydraulics.
systems etc. Feed and spindle drives may also be effected
using hydraulics.
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Mobile hydraulics
Mobile hydraulics:
Tractors, irrigation
system, earthmoving
equipment, material
handling equipment,
commercial vehicles,
tunnel boring equipment,
rail equipment, building
and construction
machineries and drilling
rigs etc.
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Automobile hydraulics
Automobiles: It is
used in the systems
like breaks, shock
absorbers, steering
system, wind shield,
lift and cleaning etc.
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Marine hydraulics
Marine applications:
It mostly covers
ocean going vessels,
fishing boats and
navel equipment.
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Aerospace hydraulics
Aerospace equipment:
There are equipment and
systems used for rudder
control, landing gear,
breaks, flight control and
transmission etc. which
are used
in airplanes, rockets and
spaceships.
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Comparison of hydraulics with other

control media
There are other technologies besides hydraulics
which can be used in the context of control
technology for generating forces, movements
and signals:
Mechanics
Electricity
Pneumatics
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HYDRAULIC OPERATION 30





Pumps
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Hydraulic Pump
A pump is the heart of the hydraulic system, convert
mechanical energy into hydraulic energy.
Main purpose of the pump is to create the flow of oil
through the system & thus assist transfer of power &
motion.
The combined pumping and driving motor unit is
known as hydraulic pump.
The hydraulic pump takes hydraulic fluid (mostly some
oil) from the storage tank and delivers it to the rest of the
hydraulic circuit.
In general, the speed of pump is constant and the pump
delivers an equal volume of oil in each revolution.
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Hydraulic Pump
The hydraulic pumps are characterized by its flow rate
capacity, power consumption, drive speed, pressure
delivered at the outlet and efficiency of the pump.
The pumps are not 100% efficient.
The efficiency of a pump can be specified by two ways:
One is the volumetric efficiency which is the ratio of actual
volume of fluid delivered to the maximum theoretical
volume possible.
Second is power efficiency which is the ratio of output
hydraulic power to the input mechanical/electrical power.
The typical efficiency of pumps varies from 90-98%.
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Hydraulic Pump
The hydraulic pumps can be of two types:
centrifugal pump
reciprocating pump
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Centrifugal pump
Centrifugal pump uses rotational
kinetic energy to deliver the fluid.
The rotational energy typically
comes from an engine or electric
motor.
The fluid enters the pump impeller
along or near to the rotating axis,
accelerates in the propeller and
flung out to the periphery by
centrifugal force as shown in
figure.
In centrifugal pump the delivery is
not constant and varies according
to the outlet pressure.
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Centrifugal pump
These pumps are not suitable for high pressure
applications and are generally used for low-
pressure and high-volume flow applications.
The maximum pressure capacity is limited to
20-30 bars.
Most of the centrifugal pumps are not self-
priming and the pump casing needs to be filled
with liquid before the pump is started.
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Reciprocating or positive displacement

pump
The reciprocating pump is a
positive plunger pump. It is
also known as positive-
displacement pump or piston
pump.
It is often used where
relatively small quantity is to
be handled and the delivery
pressure is quite large. The
construction of these pumps
is similar to the four stroke
engine as shown in figure.
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Reciprocating or positive displacement

pump
The crank is driven by some external rotating motor.
The piston of pump reciprocates due to crank rotation.
The piston moves down in one half of crank rotation, the
inlet valve opens and fluid enters into the cylinder.
In second half crank rotation the piston moves up, the
outlet valve opens and the fluid moves out from the
outlet.
At a time, only one valve is opened and another is closed
so there is no fluid leakage.
Depending on the area of cylinder the pump delivers
constant volume of fluid in each cycle independent to the
pressure at the output port.
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Classification of Hydraulic Pumps

These are mainly classified into two categories:
Pump
Hydrodynamic
Hydrostatic
(Non-Positive
(Positive displacement)
displacement)
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Positive displacement pumps

This pump ejects fixed quantity of fluid per
revolution of the pump shaft. The pump outlet
flow is constant & is not depended on the system
pressure. So they are suited for fluid power
system.
Positive displacement pumps must be protected
against overload. The reason is that, it continues
to eject fluid (even though it has no place to go)
causing an extremely rapid build up of pressure.
Example: Gear pump, Vane pump, piston pump.
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Advantages of positive displacement

pumps
PD pumps are widely used in hydraulic system
They generate high pressure
They are relatively small & enjoy very high
power to weight ratio.
They have greater flexibility of performance
under varying speed pressure requirement.
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Construction & Principal of PD pumps..

Reciprocating pump are generally cylinders with
operating as a pump. They are available in various
size, shape & driving mechanisms. Due to high
pressure they are used for specialized applications.
A pump using this principle is known as piston
pump.
Rotary pump are most common in oil hydraulics
system when low to medium pressure is the prime
consideration.
The 3 prime types are:
1) Gear, 2) Vane, 3) Screw
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Gear Pumps
Gear pump is a robust and simple positive
displacement pump. It has two meshed gears
revolving about their respective axes.
The rigid design of the gears and houses allow
for very high pressures and the ability to pump
highly viscous fluids.
They are suitable for a wide range of fluids and
offer self-priming performance.
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Gear Pumps
Based upon the design, the gear pumps are
classified as:
External gear pumps
Lobe pumps
Internal gear pumps
Gerotor pumps
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External Gear pump

External gear pumps have two mating gear in a
closed fitted housing. One of the gear is
connected to a drive shaft connected to the
prime mover. The 2nd one, the follower gear is
driven as it meshes with the driver gear.
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How external gear pump work !

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Generally gear pumps are used to

pump
Petrochemicals: Diesel oil, crude oil, lube oil etc.
Chemicals: Sodium silicate, acids, plastics,
mixed chemicals etc.
Paint and ink
Resins and adhesives
Pulp and paper: acid, soap, lye, black liquor,
lime, sludge etc.
Food: Chocolate, cacao butter, fillers, sugar,
vegetable fats and oils, animal food etc.
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Lobe Pump
Lobe pumps work on the
similar principle of
working as that of
external gear pumps.
However in Lobe pumps,
the lobes do not make
any contact like external
gear .
Lobe contact is prevented
by external timing gears
located in the gearbox.
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Lobe Pump
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Lobe Pump
Similar to the external gear pump, the lobes
rotate to create expanding volume at the inlet.
Now, the fluid flows into the cavity and is
trapped by the lobes. Fluid travels around the
interior of casing in the pockets between the
lobes and the casing.
Finally, the meshing of the lobes forces liquid to
pass through the outlet port.
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Applications
Lobe pumps are frequently used in food applications
because they handle solids without damaging the
product.
Large sized particles can be pumped much
effectively than in other positive displacement types.
As the lobes do not make any direct contact
therefore, the clearance is not as close as in other
Positive displacement pumps.
This specific design of pump makes it suitable to
handle low viscosity fluids with diminished
performance.
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Piston pumps
Piston pumps are meant for the high-pressure
applications. These pumps have high efficiency and
simple design and needs lower maintenance.
These pumps convert the rotary motion of the input
shaft to the reciprocating motion of the piston. These
pumps work similar to the four stroke engines.
They work on the principle that a reciprocating piston
draws fluid inside the cylinder when the piston retracts
in a cylinder bore and discharge the fluid when it
extends.
These pumps are positive displacement pump and can be
used for both liquids and gases.
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Piston pumps types

Piston pumps are basically of two types:
Axial piston pumps
Bent axis piston pumps
Swash plate axial piston pump
Radial piston pumps
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Axial Piston Pump

Axial piston pumps are positive displacement
pumps which converts rotary motion of the
input shaft into an axial reciprocating motion of
the pistons.
These pumps have a number of pistons (usually
an odd number) in a circular array within a
housing which is commonly referred to as a
cylinder block, rotor or barrel.
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Bent-Axis Piston Pumps

In these pumps, the reciprocating action of the
pistons is obtained by bending the axis of the
cylinder block.
The cylinder block rotates at an angle which is
inclined to the drive shaft. The cylinder block
is turned by the drive shaft through a universal
link. The cylinder block is set at an offset angle
with the drive shaft.
The cylinder block contains a number of
pistons along its periphery. These piston rods
are connected with the drive shaft flange by
ball-and socket joints. These pistons are forced
in and out of their bores as the distance
between the drive shaft flange and the cylinder
block changes.
A universal link connects the block to the drive
shaft, to provide alignment and a positive
drive.
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61

62
Swash Plate Axial Piston Pump

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Bent-Axis Piston Pumps Swash Plate Axial Piston Pump

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Radial Piston Pump

The piston pump has pistons
aligned radially in a cylindrical
block.
Pistons are placed in radial
bores around the rotor. The
piston shoes ride on an
eccentric ring which causes
them to reciprocate as they
rotate.
The eccentricity determines
the stroke of the pumping
piston.
The radial piston pump works
on high pressure (up to 1000
bar).
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Combination Pump
Two basic requirements for load lifting or load
applying by a hydraulic ram.
First, there is a need of large volume of fluid at a
low pressure when the cylinder extends or
retracts. The low pressure is required to
overcome the frictional resistance.
The second requirement is that a high pressure
is needed, when the load is gripped.
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Combination Pump
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Combination Pump
In this system two separate pumps are driven by a
common electrical motor.
Pump P1 is a high pressure low volume pump and
pump P2 is a high volume low pressure pump.
The hydraulic system is associated with relief valves
RV1 and RV2 and a one-way check valve CV1.
This kind of arrangement allows the fluid flow from
left to right.
This kind of arrangement saves energy as the large
volume of fluid from pump P2 is returned to the
tank at a very low pressure, and only a small volume
of fluid from pump P1 is returned at a high pressure.
Hydraulic Fluid & Properties
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Job perform by the hydraulic oil

They have the following primary tasks:
Power transmission (pressure and motion
transmission)
Signal transmission for control
Secondary tasks:
Lubrication of rotating and translating components to
avoid friction and wear
Heat transport, away from the location of heat
generation, usually into the reservoir
Transport of particles to the filter
Protection of surfaces from chemical attack, especially
corrosion
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Hydraulic fluids requirements

Functional
Good lubrication characteristics
Viscosity should not depend strongly on temperature
and pressure
Good heat conductivity
Low heat expansion coefficient
Large elasticity modulus
Economic
Low price
Slow aging and thermal and chemical stability long
life cycle
71
Hydraulic fluids requirements

Safety
High flash point or in certain cases not
inflammable at all
Chemically neutral (not aggressive at all against
all materials it touches)
Low air dissolving capability, not inclined to foam
formation
Environmental friendliness
No environmental harm
No toxic effect
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Properties of Hydraulic Fluid.

Good Lubricity Low Foaming Tendency
Stable Viscosity Fire Resistant
Characteristics Prevent Rust Formation
Good Heat Dissipation Non-toxic, Easy to handle &
Flash Point Available
73
Good Lubricity
The component in a hydraulic system contain
many surface which are in close contact and
which move in relation to each other. The
hydraulic fluid must separate and lubricate such
surfaces. Protection against wear is a principal
reason for selecting a fluid having good
lubrication characteristics as a hydraulic
medium.
74
Good Heat Dissipation

An important requirement of the fluid is to carry
heat away from the working parts.
Pressure drops, mechanical friction, fluid
friction, leakages, all generate heat.
The fluid must carry the generated heat away
and readily dissipate it to the atmosphere or
coolers.
Therefore high thermal conductivity and high
specific heat values are desirable in the fluid
chosen.
75
Flash Point
The flash point of a hydraulic oil is defined as
the temperature at which flashes will be
generated when oil is brought into contact with
any heated matter, e.g., a heat stick.
Low flash point oils are not use as Hydraulic Oil.
76
Low Foaming Tendency

Foam results from air or other gases becoming
entrained in the hydraulic fluid. Air enters a
hydraulic system through the reservoir or through
air leaks within the system.
A hydraulic fluid under high pressure can contain a
large volume of dissolved or dispersed air bubbles.
When this fluid is depressurized, the air bubbles
expand and produce foam. Because of its
compressibility and poor lubricating properties,
foam can seriously affect the operation and
lubrication of machinery.
Proper foam inhibitors modify the surface tension
on air bubbles so they more easily break up.
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Fire Resistant
Fire resistance is one of the properties that is
optional in a good usable hydraulic fluid.
The commonly used hydraulic liquid are
petroleum derivative, and consequently they
burn vigorously once they pass the point.
For critical application, artificial or synthetic
hydraulic fluid are used which have high fire
resistances. Various grades of fluids with high
water content are also available now a days for
oil hydraulic system.
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Stable Viscosity Characteristics

Viscosity is a measure of a hydraulic fluid's resistance to
flow. It is a hydraulic fluid's most important
characteristic and has a significant impact on the
operation of the system.
When a hydraulic oil is too thin (low viscosity), it does
not seal sufficiently. This leads to leakage and wear of
parts. When a hydraulic oil is too thick (high viscosity),
the fluid will be more difficult to pump through the
system and may reduce operating efficiency.
All hydraulic fluids must be able to retain optimum
viscosity during operation in cold or hot temperatures, in
order to consistently and effectively transmit power
79
Prevent Rust Formation

In many systems, water can enter as condensation
or contamination, and mix with the hydraulic oil.
Water can cause rusting of hydraulic components.
In addition, water can react with some additives to
form chemical species which can be aggressive to
yellow metals.
Hydraulic oil formulations contain rust and
corrosion inhibitors which prevent the interaction of
water or other chemical species from attacking
metal surfaces.
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Non-toxic, Easy to Handle & Available

These characteristics refer to the interaction of
the fluid with people who repair, handle, use or
pay for hydraulic system fluid.
Obviously, it is desirable that the fluid be as
simple to handle and as available and cheap as
possible.
81
Hydraulic oil used in India.

Indian oil corporation limited(IOCL) has marked oil
used for hydraulic system are termed as Circulating
and Hydraulic Oils.
These oils are recommended for hydraulic system,
circulation system of industrial gearboxes, air
compressors requiring turbine quality oil and for
plain and anti-friction bearings of turbo feed pumps,
turbo blowers, etc.
These Oils can be used for lubrication of
intermittently operating turbo generator sets where
oil is changed after short duration.
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Fluid power systems

HYDRAULIC MACHINE 83
PUMP ACTUATOR
PUMP ACTUATOR
PUMP ACTUATOR
PUMP ACTUATOR
PUMP ACTUATOR
PUMP ACTUATOR
PUMP ACTUATOR
PUMP ACTUATOR
PUMP ACTUATOR
PUMP ACTUATOR
PUMP ACTUATOR
PUMP ACTUATOR
PUMP ACTUATOR
PUMP ACTUATOR
PUMP ACTUATOR
PUMP ACTUATOR
Hydraulic POWER PACK
100
Power Pack
The hydraulic power unit
P T
(power supply unit) provides
the energy required for the
hydraulic installation. Its most
important components are
The reservoir (tank) , Ts
Drive (electric motor),
Hydraulic pump,
Pressure relief valve ,
Filter and cooler.
The hydraulic power unit may
also act as a carrier for other
devices (gauges, directional
control valves).
Hydraulic Symbols
Why we need Hydraulic Symbols ?
102
SCHEMATIC REPRESENTATION
103

104

105

106

107

108

109
M
110
M
DCV
Filter
Tank
Sanjay Humania
20-01-2016
111
112
Graphical representation of hydraulic

and pneumatic elements
The hydraulic and pneumatic elements such as cylinders and
valves are connected
through pipelines to form a hydraulic or a pneumatic circuit. It is
difficult to represent the
complex functioning of these elements using sketches. Therefore
graphical symbols are
used to indicate these elements. The symbols only specify the
function of the element
without indicating the design of the element. Symbols also indicate
the actuation method,
direction of flow of air and designation of the ports. Symbols
are described in various
documents like DIN24300, BS2917, ISO1219 and the new
ISO5599, CETOP RP3 and
the original American JIC and ANSI symbols.
113

The symbol used to represent an individual
element display the following characteristics:
Function
Actuation and return actuation methods
Number of connections
Number of switching positions
General operating principle
Simplified representation of the flow path
114

The symbol does not represent the following
characteristics:
Size or dimensions of the component
Particular manufacturer, methods of construction
or costs
Operation of the ports
Any physical details of the elements
Any unions or connections other than junctions
115
Symbols for ports

Earlier the ports were designated with letter
system. Now as per ISO5599 the ports are
designated based on number system.
116
Symbols for ports

117
Graphical symbols of hydraulic

elements and equipment
118

119

120
Circuit symbols for

121
Directional control valves

122

123
4/3way directional control valves

124
Circuit symbols for manual operation

125
Circuit symbols for manual operation

126
Circuit symbols for flow control valves

127
Circuit symbol for pressure valves

128
Circuit symbols for non-return valves

Hydraulic Actuators
130
Hydraulic Actuators
The fluid discharged by the pump is directed to
the hydraulic actuator. The actuator convert the
pressure energy of the fluid into mechanical
energy. There are 3 basic type of hydraulic
actuator.
The actuators convert the fluid pressure to a
suitable linear or rotary motion.
Linear motion Hydraulic cylinder
Rotary motion Hydro motor
Rotary motion Semi-rotary actuator
131
Hydraulic cylinders
A hydraulic cylinder is a device, which
converts fluid power into linear mechanical force
and motion. It usually consists of a movable
element, a piston and a piston rod operating
within a cylindrical bore.
132
Parts of a hydraulic cylinder

A hydraulic cylinder consists of the following
parts
Cylinder barrel
Piston
Piston rod
Bush
Cylinder head and cap
133
Type of hydraulic cylinder

Single acting
cylinders
Hydraulic
cylinder
Double acting
cylinders
134
Single acting cylinder

In the case of a single acting cylinder, only the
piston side is pressurized with hydraulic fluid.
The cylinder can thus carry out work only in one
direction. The fluid which flows into the piston
chamber causes a pressure to build up the
surface of the piston. The piston travels into its
forward end position. The return stroke is
effected by a spring, the dead weight of the
piston rod or an external load
135
Single acting cylinder.

136
Plunger type single acting cylinder

In the case of plunger
cylinders, the piston and rod
form a single component. Due
to the design of the cylinder,
the return stroke can only be
effected by external forces. The
cylinders can therefore
generally be installed only
vertically.
137

138

139
Application of single acting cylinder

140
Double acting cylinders

In the case of double acting cylinders, both
piston surfaces can be pressurized. A working
movement can thus be performed in both
directions.
With double acting cylinders with a single-sided
piston rod, different forces and speeds are
obtained on the advance and return strokes due
to the difference in area between the piston
surface and annular piston surface.
141
Double acting cylinders

142
Application of double acting cylinders

143
Double acting cylinder with end

position cushioning
Cylinder with end position cushioning are used
to brake high stroke speeds smoothly and
prevent hard impacts at the end of the stroke.
Shortly before the end position is reached, the
cross- section for the outflow of fluid is reduced
by the built-in cushioning pistons and then
finally closed. The hydraulic fluid is then forced
to escape through a flow control valve.
144
Cushioning Cylinder
145
End position cushioning

The piston is a short distance
before its end position; the
hydraulic fluid on the piston-
rod side must escape via the
adjustable flow control valve
above the piston rod
This type of end position
cushioning is used for stroke
speed between 6 m/min and
20 m/min. At higher speed,
additional cushioning or
braking devices must be used
146
End position cushioning

The piston rod is on its return
stroke; in this flow direction,
the non-return valve below the
piston rod is opened, thus by-
passing the flow control valve.
The piston rod retracts at
maximum speed.
147
Double-acting cylinder with cushioning

148
Telescopic cylinder
Often cylinder & rod length does not fit in the
machine. In that case the piston rod is also used as a
piston barrel and a second piston rod is used.
These kinds of cylinders are called telescopic
cylinders. If we call a normal rod cylinder single
stage, telescopic cylinders are multi-stage units of
two, three, four, five or more stages.
In general telescopic cylinders are much more
expensive than normal cylinders. Most telescopic
cylinders are single acting (push). Double acting
telescopic cylinders must be specially designed and
manufactured.
149
Telescopic cylinder
Hydraulic Motors
151
Hydraulic Motors
In hydraulic system generally hydraulic motor
provide rotational movement. A hydraulic motor
transform hydraulic energy into mechanical energy
which is applied to a resistance object by means of a
shaft connected with the motor.
Hydraulic motor closely resemble hydraulic pumps
in construction & size. The only difference is that
instead of pushing the fluid as the pump does, in
hydraulic motor the rotating elements(i.e. vanes,
gear, piston, etc.) are pushed by the oil pressure to
enable the motor shaft to rotate & thus develop the
necessary turning torque & continuous rotational
motion.
152
Construction of External Gear Motor

153
Construction of Radial Piston Motor.

154
Hydraulic motor used in FESTO training

kit
155
Semi rotary actuator

The limited angle rotary
actuator is applied when the
shaft has to rotate over a
limited angle. The animation
shows how this simple
actuator works: in this case the
shaft can rotate over an angle
of about 270 degrees. This type
of actuator is, among others,
used as a rotator actuator on
(small) cranes and excavators
Hydraulic valves
157
Hydraulic valves
The pressure energy is fed to the actuator
through a number of control block called valves.
Various type of valve are used in hydraulic
system to control or regulate the flow medium.
Basically valves are expected to control:
Direction
Pressure
Flow
Other special functions.
158

These valves control the direction of flow of the
hydraulic fluid and, thus, the direction of motion
and the positioning of the working components.
Directional control valves may be actuated
manually, mechanically, electrically,
pneumatically or hydraulically. They convert and
amplify signals(manual, electric or pneumatic)
forming an interface between the power control
section and the signal control section.
159

160
Symbol design of valves.

Method of designation of valve
The basic symbol for control valve is a square.
Two or more squares are used.
Each square representing the switching position
provided by the valve.
1. Two position valve.
2.Three position valve.

161
Symbol design of valves..

Lines in the boxes are used to show flow path
with arrow indicating direction of flow.
FLOW
The shut off position is indicated by the line

drawn at right angle to the horizontal line inside
the rectangle.
SHUT OFF / NO FLOW
162
Pipe connections
The pipe connections i.e. inlet and outlet ports to
the valve are indicated by lines drawn on outside
of the box and right angle to the horizontal line .
The first position from left indicates the rest,
initial or neutral position when the valve is not
actuated.
The second position or square from left indicates
actuated position.
163
Pipe connections
Single position (initial)
Two position valve
Three position valve

164
Commonly used direction control

valves
Direction control valve is used to control or to
change the direction or to start or stop the fluid
flow only on the receipt of any signal which may
be mechanical, electrical or a fluid pressure pilot
signal.
Direction control valves are described by
number of ports and number of positions
n / n way valve
( n = 1, 2, 3,)
165
Way/position
Way Valve Ports Positions
2/2 2 (1 input , 1 output) 2
3/2 3 (1 input, 1 output, 1 tank) 2
166
(2/2 ) On/off valve

The most basic direction control valve is the
simple on/off valve. A simple version is shown
symbolically below.
167
(2/2 ) On/off valve

2/2 way valve normally closed
Not actuated
168
(2/2 ) On/off valve

2/2 way valve normally closed
Actuated
169
(2/2 ) On/off valve

used in FESTO training kit
170
(3/2 ) direction control valve

The three way version of the above valve which
allows the outlet port to be connected to either
the pump or the reservoir is shown below
171

Normally closed
Not activated
172

Normally close
Activated
173
(3/2 ) direction control valve in FESTO

training kit
174

Normally close
Not Activated
175

Normally close
Activated
176
(4/2 ) direction control valve in FESTO

training kit
177

178

179

180

181

182

183

184

4/3 way mid-position recirculation / tandem
mid-position
Middle position is activated
185

4/3 way mid-position recirculation / tandem mid-
position
Position 1 is activated
186

4/3 way mid-position recirculation / tandem
mid-position
187

4/3 way mid position cutoff / all ports blocked
mid position
188

mid position
189

mid position
190
(4/3) direction control valve in FESTO

training kit
191
(4/3) direction control valve

192
(4/3) direction control valve

193
Non-Return /Check valve

194

195

(Direction control valve)
Check Valves are simply valves which provide
reasonably unrestricted flow in one direction
and stop the flow in the other direction. A light
spring is generally used to retain the valve to a
closed position on near zero flow.
196

(Direction control valve)
197
Non-Return /Check Valves

198
Pilot operated check valves

As opposed to the simple non
return valve, pilot operated
check valve may also be
operated in the direction of
close.
These valves are used, for
example:
To isolated work circuits
under pressure
To prevent the load from
dropping, if a line should
break
To prevent creep movements
hydraulically loaded
actuators
199
Pilot operated check valve

200
Pilot operated check valve

201
Pre-fill valve
202
Pre-fill valve
Pre-fill valve are large size
hydraulic pilot operated check
valve. They are used mainly to
pre fill large cylinder volumes
and to isolate the main
working circuit under
pressure.
203
Flow rate
Flow rate is the term used to
describe the volume of liquid
flowing through a pipe in a
specific period of time. For
example, approximately one
minute is required to fill a10
litre bucket from a tap. Thus,
the flow rate amounts to 10
l/min.
204
Flow rate
In hydraulics, the flow rate is designated as Q.
The following equation applies:
Q =Flow rate
V = Volume
t = time
205
Flow control valves

The speed of the actuators needs to be altered as
per operational requirement. For this purpose
hydraulic systems use flow control valves.
These interact with pressure valves to affect the
flow rate. They make it possible to control or
regulate the speed of motion of the power
components. Where the flow rate is constant,
division of flow must take place. This is generally
effected through the interaction of the flow
control valve with a pressure valve.
206
Flow control valves

207
Flow control valve

The main classification of the flow control valve
are:
Flow control valve
Non pressure Pressure

compensated compensated.
208
Non-pressure compensated flow control valve
The simplest type of flow control valve is a

needle valve. The needle valve has a pointed
stream that can be adjusted manually to control
the rate of flow through the valve.
209
Non-pressure compensated flow

control valve
210
Non-pressure compensated flow

control valve
211
Non-pressure compensated
unidirectional flow control valve
In most fluid power
application needle valve with
integrated check valve is used
to control the flow rate. This
enable a regulated flow in one
direction with free flow in the
reverse direction.
212
Non-pressure compensated
unidirectional flow control valve
213
Pressure compensated flow control

valve
The flow through the valve varies as the square
root of the pressure drop across it. So any
changes in pressure at the outlet and inlet
changes the flow through the valve.
But pressure compensation flow control
automatically adjust to pressure changes and
maintain a constant pressure drop from inlet to
outlet, thus providing constant flow.
214

valve
215

valve
216
Location of flow control valves

The location of flow control valves with respect
to other component & the work is quit important
because it has an effect on the characteristics of
the circuit performance.
There are 2 basic type of location of a flow
control valve in any hydraulic system.
Meter in circuit
Meter out circuit
Bleed off circuit
217
Meter in circuit
In this type of circuit, the valve is located in the
pressure line leading to the work cylinder.
The flow entering into the work cylinder is first
controlled through the valve.
Meter in circuit are generally used when the
load characteristics are constant & positive. For
free reverse flow, generally a check valve is
provided parallel to the flow control valve.
For example: A hydraulic table feed on a surface
grinder would require controlled rate of travel.
218
Meter out circuit

In this type of circuits, the flow control valve is
installed on the return side of the cylinder so that it
controls the speed of the working cylinder by
monitoring the discharge flow.
The meter out circuit is commonly used in
machine tools that require precise control of fluid on
discharge from the exhaust side of the cylinder.
The machine tools like mills and drills often
required large restraining force to prevent excessive
pull on the cylinders.
Pressure control valves
Why we need Pressure control
valves ?
220

221

222

223

224

225

226

227

228

229

230

231

232

233

234

235

236

Oil energy does the work due to pressure in
the oil system. In a mechanical or hydraulic
system there may be a need to increase or
decrease the oil pressure depending on the
specific requirement. Hence a group of valves
called pressure control valve have been
designed.
237

238
Pressure Relief Valves

Relief valves are generally spring loaded valves
which include a plug over a discharge port which
is lifted against an spring force if the system
pressure exceeds a certain value. This opens the
flow to the discharge port relieving the pressure.
239

240

(internal pilot operated version )
The pilot operated version enables more
accurate control of the setting and a lower relief
setting can be accommodated
241

(internal pilot operated version )
242

(Externally controlled/remote pilot)
The valve opens when pressure at X port is more than spring

force.
243

244

245
Application of Pressure Relief Valve
It can be used
To relive excessive pressure / to protect pump /
other parts
To limit the system pressure
As a back pressure valve / counterbalancing
valve
As a sequence valve
246
Pressure Reducing Valve

This type of valve is used to maintain reduced pressure
in specified location of a hydraulic system. Normally it is
an open valve.
A pressure reducing valve is one which used a spring
loaded spool to control the downstream pressure.
If the downstream pressure is below the value pressure,
fluid will flow freely from the inlet to the out let.
When the outlet pressure increases the valve setting , the
spool moves to partially block the outlet port.
If the valve is closed completely by the spool, it could
cause the downstream pressure to buildup above the
valve setting. To avoid this, a drain line is provided to
drain the fluid to the tank.
247

248

249
Application of Pressure Reducing

Valve
In oil driven spot welding guns, the control of the
pressure is important for good welding. In that
hydraulic system both welding gun and the clamp
are powered by the same pump/power pack.
A pressure reducing valve which is placed in
between the welding gun and main pressure, which
will regulate the pressure on the spot welding gun.
The clamp pressure is determined by the pump
relief valve setting.
250
3 way Pressure
Reducing & Relief valve
This valve is combination of 2 way pressure
regulator & PRV
251
3 way Pressure
252
3 way Pressure
253
Deceleration valve
A deceleration flow control valve gradually reduce
its flow rate to provide deceleration of the heavy
loads. On some machine it is desirable to have a
skip-feed arrangement. This is accomplished by
having a cam operated deceleration valve.
The cam operated deceleration valve is connected in
parallel with the meter-out flow control valve to
provide an adjustable minimum flow when the main
flow path is closed.
Rapid forward movement will take place when the
valve is in the open condition. Cam on the slide act
to close the valve gradually.
254
Deceleration valve
255
Deceleration valve
Flow from the rod end of the cylinder is
gradually restricted & this will slow down the
movement & the feed phase starts.
Return speed is at the maximum when flow from
the pump to end bypasses the flow control valve
by flowing through the check valve.
256
Deceleration valve
257
Shutoff valve
Others components
259
Bourdon-tube pressure gauge

260
PRESSURE GAUGE
This gauge is sometimes known as Bourdons
pressure gauge as it employs a Burdon Pressure
Tube.
It is a phosphor-bronze tube oval in section and
circular in form. When pressure is applied to the
tube, its tends to straighten and this move of the
tube is transferred to a needle or pointer through a
link, sector arm & a pinion assembly.
The pressure can be read out from the pointer
scanning a graduated dial.
The accuracy of the pressure gauge should be within
(+) or (-) 1 to 2% of the reading value.
261
Components of Bourdon Tube Pressure

Gauge
262
How Bourdon Tube Pressure Gauge

Works
263
Why internal chamber of the gauge is

filled with liquid?
To maintain the accuracy of the pointer
movement and to avoid damage to the link
mechanism, the entire internal chamber of the
gauge is filled with transparent liquid like
glycerin or any other oils.
This will suppress any vibration and thus will
ensure accuracy of the pressure reading.
Accumulators
265
Accumulator
Hydraulic accumulator is an accessory of a hydraulic
system
A hydraulic accumulator is a pressure storage reservoir
in which a non-compressible hydraulic fluid is held
under pressure by an external source.
The external source can be a spring, a raised weight, or a
compressed gas. An accumulator enables a hydraulic
system to cope with extremes of demand using a less
powerful pump, to respond more quickly to a temporary
demand, and to smooth out pulsations. It is a type of
energy storage device.
266
Types of Hydraulic Accumulator

The function of hydraulic accumulator is to store
pressurized oil.
Types:
Weighted accumulator
Spring loaded accumulator
Gas-charged accumulator
267
Weight loaded type accumulator

This is the oldest type of accumulator. This consist
of a vertical, heavy steel cylinder which incorporates
a piston with packing to prevent leakage.
A dead weight is attached to the top of the piston.
The force of gravity of the dead weight provides the
potential energy in the accumulator.
The main disadvantages of this of accumulator is its
large size and heavy weight makes it unsuitable for
mobile equipment.
268
Weight loaded type accumulator

269
Spring loaded accumulator

A spring loaded accumulator is
similar to the weight loaded
type, except that the piston is
preloaded with a spring.
270
Bladder type
The three types of gas-charged
accumulators are bladder,
piston and diaphragm.
The most popular of these is
the bladder type. Bladder
accumulators feature fast
response (less than 25
milliseconds), a maximum gas
compression ratio of around
4:1 and a maximum flow rate
of 15 liters (4 gallons) per
second.
271
Accumulator used in FESTO kit

Design of hydraulic circuits
273
Simple hydraulic circuit

Make a double acting cylinder
forward and backward.
274
Simple hydraulic circuit

Rotate a hydraulic motor
clockwise and anti-clockwise.
275
Regenerative Circuit
A regenerative circuit is used to speed up the
extending speed of a double acting hydraulic
cylinder. Both ends of the hydraulic cylinder are
connected in parallel so that one port of the four
way valve is blocked.
When the DCV is shifted to its left mode, the
fluid bypasses the DCV and enters into the rod
end of the cylinder. Fluid in the blank end drains
back to the tank through the DCV as the cylinder
retracts.
276
Regenerative Circuit
Normal circuit:
277
Pilot operated Check Valves-

Application 1
278

Application 2
279

Application
280
Meter in circuit
281
Meter out circuit

282
PRESSURE COMPENSATED FLOW

CONTROL VALVE APPLICATION
283
Application of pressure reducing valve

284
3 way Pressure
285
Counterbalance Application
286
Automatic cylinder reciprocating

circuit using sequential valve
287
Counterbalance Application 2
288
Sequence vale application A+b+ then

AB-
289
Sequence vale application

290
Remote relief valve sequence valve

A+B+ then AB-
291
HYDRAULIC MOTOR CONTROL

SEQUENCE APPLICATION
Industrial Hydraulic Systems
293
Calender feeding device

Single-acting cylinder [Ex 1]
Rolls of paper are lifted into a
calender by a lifting device. The
lifting device is driven by a
plunger cylinder (single-acting
cylinder). When the hydraulic
power pack is switched on, the
pump output flows directly to
the cylinder. A 2/2-way valve,
which is closed in its normal
position, is fitted in a branch
line leading to the tank. A non-
return valve is used to ensure
that the pump is protected
against the oil back pressure. A
pressure relief valve is fitted
upstream of the non return
valve to safeguard the pump
against excessive pressures.
294
Calender feeding device

295
Hardening furnace
The cover of a harden furnace
is to raised by a single acting
cylinder. The cylinder is
activated by a 3/2 way valve. A
9 kg weight is attached to the
cylinder to represent the load.
What are the necessary
components?
Draw the hydraulic circuit
diagram.
Practical assembly of circuit.
296
Hardening furnace
297
Furnace door control

Double-acting cylinder [Ex 3]
A furnace door is
opened and closed by
a double acting
cylinder. The cylinder
is activated by a 4/2
way valve with spring
return. Speed of
opening and closing
are to be controlled
separately.
298
Furnace door control

Double-acting cylinder [Ex 3]
299
Conveyor tensioning device

4/3-way valve with bypass to pump

[Ex 4]
Parts are fed through a drying oven on a steel
chain conveyor belt. It must be possible to
correct the tracking of the belt by means of a
tensioning device to ensure that the belt does
not run off its rollers. This device consists of a
steel roller fixed at one end and movable at the
other by means of a double-acting cylinder.
Hydraulic power must be available continuously.
The hydraulic system must switch to the
recirculation (H in mid-position 4/2 way valve)
condition when the directional control valve is
not actuated. The clamping station causes a
continuous counter force to act on the cylinder.
A piloted non-return valve is used to prevent
creepage of the piston rod of the positioning
cylinder as a result of oil leakage losses in the
directional control valve.
300
Conveyor tensioning device

4/3-way valve with bypass to pump

[Ex 4]
301
Drilling machine [Ex 5]

In a automated drill machine,
first the clamp cylinder should
extend and clamp the work
piece. Then the work cylinder
should extend to drive a
spindle to drill a hole in the
work piece. Then the work
cylinder retracts the drill
spindle and the clamp cylinder
retracts to release the work
piece for removal.
302
Drilling machine [Ex 5]

303
Bulkhead door
Hydraulic clamping of a cylinder [Ex 6]
A double-acting cylinder is
used to open and close a
bulkhead door. Closing must
be carried out smoothly and at
a constant adjustable speed.
The speed is adjusted by
means of a one-way flow
control valve. A pressure relief
valve must be fitted to provide
counter-holding and prevent
the heavy door from pulling
the piston rod out of the
cylinder during the closing
operation.
304
Bulkhead door
Hydraulic clamping of a cylinder [Ex 6]
305
Skip handling Varying load [Ex 7]

The loading and unloading of
skips from a skip transporter
is carried out using two
double-acting cylinders. Each
cylinder is subject to varying
loads tractive load during
unloading and compressive
load during loading. The skip
should be raised and lowered
at a slow constant speed. Each
cylinder must therefore be
hydraulically clamped on both
sides.
306
Skip handling Varying load [Ex 7]

307
Cold-store door Accumulator [Ex 8]

A heavy cold-store door is
opened and closed by a
hydraulic cylinder. A hydraulic
accumulator is to be installed
to allow the door to be closed
in the case of an electrical
power failure. This will permit
the cold-store door to be
opened and closed a number
of times. A 4/2-way valve is to
be used to activate the
cylinder. This valve should be
connected up in such a way
that the piston rod is advanced
with the valve in its normal
position.
308
Cold-store door Accumulator [Ex 8]

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